en
0

Shopping Cart

closeCart
€0.00

What You Need To Know About BMW Swirl Flaps and How To Solve The Problem With Them

  • /
  • Blog
  • /
  • What You Need To Know About BMW Swirl Flaps and How To Solve The Problem With Them
Post Name
28.05.2024

Swirl flaps are a BMW system that has been introduced to help burn the fuel mixture in the cylinder better due to the fact that diesel engines do not have throttle valves and it is not possible to adjust the air-fuel ratio. A diesel engine without vortex valves operates between a poor and a rich fuel mixture, because the only way to regulate it is through fuel injection.

Design of the first generation swirl flaps that are made of made of metal.

Unfortunately, swirl flaps are responsible for countless damaged engines and costly repairs due to design errors or metal fatigue. Once damaged, the cylinder sucks them in and causes great damage.

This is how damaged valves damage the cylinder.

Typical swirl flaps  suction damage.

The vortex valves are positioned in the inlet and are controlled by vacuum (DDE 4.0) or electrically (DDE5.0 / DDE6.4) by the engine ECU.

Effects of malfunctioning valves:

  • Swirl valves are  stuck in open position: Deterioration of exhaust gas performance at lower speeds.
  • Swirl valves are stuck in closed position: Approximate power loss of 10% at high engine speeds.

How swirl flaps work:

Performance characteristics:

The vortex valves are in the closed position, at low engine speeds and small amounts of fuel injected (controlled by the ECU card).

They open under the following conditions:

  1. coolant temperature <14 ° C OR * fuel quantity> 24 mg OR
  2. engine speed 2250 rpm OR
  3. inlet air temperature <-5 ° C

BMW and Pierburg have decided to produce diesel engines with metal vortex valves. The speed at which the pistons in the diesel engine operate is at least 60 rpm, so a sucked vortex valve will break and cause a number of damages inside the engine.

In most cases, one or more pistons are severely damaged, as a bonus you get valves, in some cases a head or turbocharger. And this combination with a BMW engine is like a cumulative jackpot  🙂

In 2004, BMW began work on the problem and improved the design, however, a number of owners reported ongoing problems in this area.

The solution to this problem is by removing the vortex valves and plugging, which does not affect the performance of the engine and at the same time, you can safely pass the exhaust test.

Engines:

M47 (136hp VP44 fuel pump) has no valves.

M47N common rail engine (including M47N / M47TU / M47TUD20) (150hp. Face lift model from 2001 -) has valves.

M57 engines (M57D) (525d & 187hp. 330d) cars with manual transmission do not have valves, but those with automatic have.

M57N engines (M57TUD) (525d & 330d 204hp) have vortex valves.

Ruined swirl flaps:

The plugs that replace the vortex valves are easy to find on the internet, but you can also find them here on our website.

Typical plugs:
 

Disassembly of vortex valves:

The vortex valves can be safely dismantled and in most cases if they are  removed properly no loss of power is felt.

Final list of models for which vortex valves are installed:

Engine: M47N/M47TU/M47TUD20

Applications:

* 110 kW (148 hp) and 330 N·m (243 lb·ft)

o E46 320d 2001-2005

o E83 X3 2.0d (up to end of 2006)

Engine: M47TU2D20

The engine was updated again in 2004 as the M47TU2D20. Still at 1995 cc, it produced more power across the range.

Applications:

* 120 kW (161 hp) and 340 N·m (251 lb·ft)

E60/E61 520d

E87 120d

E90/E91 320d

E83 X3 2.0d (end of 2006 onwards)

Engine: M57/M57D25

M57D25 was introduced in 2000.

Applications:

* 166 PS (122 kW; 164 hp) at 4000 rpm, 350 N·m (260 lb·ft) at 2000-2500 rpm with a 4750 rpm redline, models:

2000-2003 E39 525d *Vehicles With Automatic Transmission ONLY*

Engine: M57N/M57TU/M57TUD25

M57TUD25 was introduced in 2004.

Applications:

* 177 PS (130 kW; 175 hp) at 4000 rpm, 400 N·m (300 lb·ft) at 2000-2750 rpm models:

E60/E61 525d

Engine: M57/M57D30

M57D30, also called M57D29, was introduced in 1998.

Applications:

* 184 PS (135 kW; 181 hp)@4000, 390 N·m (290 lb·ft)@1750-3200 models:

E39 530d *Vehicles With Automatic Transmission ONLY*

E46 330d/330xd *Vehicles With Automatic Transmission ONLY*

* 184 PS (135 kW; 181 hp)@4000, 410 N·m (300 lb·ft)@2000-3000 models:

E38 730d *Vehicles With Automatic Transmission ONLY*

E53 X5 3.0d

* 193 PS (142 kW; 190 hp)@4000, 410 N·m (300 lb·ft)@1750-3000 models:

E38 730d

E39 530d

Engine: M57N/M57TU/M57TUD30

M57TUD30 was introduced in 2002. It originally produced 160 kW (215 hp) at 4000 rpm and 500 N·m (370 lb·ft) at 2000-2750 rpm, but was tweaked for 150 kW (201 hp) at 4000 rpm and 410 N·m (300 lb·ft) at 1500-3250 rpm for 2003 and again for 200 kW (268 hp) at 4000 rpm and 560 N·m (410 lb·ft) at 2000-2250 rpm in 2004.

Applications:

* 204 PS (150 kW; 201 hp)@4000, 410 N·m (300 lb·ft)@1500-3250 models:

E46 330d/330Cd/330xd

E83 X3 3.0d

* 218 PS (160 kW; 215 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E53 X5 3.0d

E60/E61 530d/530xd

E65 730d

* 272 PS (200 kW; 268 hp)@4000, 560 N·m (410 lb·ft)@2000-2250

E60/E61 535d

* 245 PS (180 kW; 242 hp)@4000, 500 N·m (370 lb·ft)@2000-2250

* 286 PS (210 kW; 282 hp)@4000, 580 N·m (430 lb·ft)@2000-2250

Engine: M57TU2D30

M57TU2D30 was introduced in 2007, making its debut in the facelifted E60 and E61.

* M57TU2D30-UL: 197 PS (145 kW; 194 hp)

* M57TU2D30-OL: 235 PS (173 kW; 232 hp)@4000, 500 N·m (370 lb·ft)@2000-2750

* M57TU2D30-TOP: 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft)

Applications:

* 197 PS (145 kW; 194 hp), 400 N·m (300 lb·ft) models:

E90/E91/E92 325d

E60/E61 525d/525xd

* 231 PS (170 kW; 228 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E65 730d

E90/E91 325d

E90/E91 330d/330xd

* 235 PS (173 kW; 232 hp) models:

E60/E61, BMW E70, BMW E71

* 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft) models:

E60/E61 535d

E70 X5 3.0sd

E71 X6 xDrive35d

E83 X3 3.0sd

E90/E91 335d

The above models are listed for information only if you want to to make sure your engine has valves installed, please contact a competent person.

Please note that the information described above is for informational purposes only and does not claim to be reliable. Mr-key.com is not responsible for any repair work you undertake that is related to the topic described in this article.

Related Posts

How to Locate Your Key Code for a Replacement
20.08.2024

How to Locate Your Key Code for a Replacement

Losing a key can be a hassle, but the process of getting a replacement becomes much easier if you can locate the key code. The key code is a unique combination of letters and numbers that identifies the specific cut and type of your key. This code is essential for accurately replicating a new key, whether it’s for your car, house, or another type of lock. This guide will help you understand where to find your key code and what steps you can take if the code isn’t easily accessible. Why the Key Code is Important The key code is essentially a blueprint for your key. It tells a locksmith or dealer exactly how to cut a new key that will work with your lock. Without this code, creating a replacement key can be a trial-and-error process, which can be time-consuming and costly. Additionally, for certain types of keys, such as those for cars with transponder chips, the key code is necessary for programming the electronic components of the key. Step 1: Inspect Your Key and Lock The first and most straightforward step is to inspect your key and lock for the key code. For many keys, especially older models, the code is engraved or stamped directly onto the key itself. This is common with car keys, where the code may be found on the metal part of the key blade. In some cases, the code might be on the plastic casing of the key, especially if it’s a newer model with electronic components. If the key itself doesn’t have the code, check the lock. The key code is sometimes inscribed on the lock’s cylinder or on a small metal plate attached to the lock. This is more common with padlocks or specialized security locks. If you’re dealing with a door lock, you might need to remove the lock from the door to inspect it closely. Step 2: Review Documentation and Original Packaging If you can’t find the key code on the key or lock, the next step is to review any documentation or packaging that came with the key. For vehicles, the key code is often provided in the owner’s manual or on a key tag that was given to you at the time of purchase. This tag is usually small and easily misplaced, so it’s worth checking any old documentation or vehicle paperwork you might have. For other types of keys, such as those for padlocks, cabinets, or office furniture, the key code might be printed on the original packaging or on warranty cards. These are often overlooked, but they can be invaluable when you need a replacement key. Step 3: Contact the Manufacturer or Dealer If the key code isn’t visible on the key, lock, or documentation, your next step should be to contact the manufacturer or dealer. Most car manufacturers, for example, keep a record of key codes based on the Vehicle Identification Number (VIN). By providing your VIN to a dealership, they can usually retrieve the key code and either cut a new key for you or give you the information needed to get one cut elsewhere. For other types of keys, such as those for cabinets or padlocks, contacting the manufacturer can also be helpful. Provide them with details about the product, such as the model number and any serial numbers, and they may be able to provide the key code or a replacement key directly. Step 4: Professional Locksmith Assistance If you’ve exhausted all other options, a professional locksmith is your best bet. Locksmiths have specialized tools and knowledge that allow them to decode locks or determine the correct key code even when it’s not visible or available through documentation. They can often cut a new key based on the lock itself, bypassing the need for the original key code entirely. Locksmiths are particularly useful if you’re dealing with older locks, unique security systems, or if the key code is no longer accessible through traditional means. They can also help with programming transponder keys for vehicles, ensuring that your new key not only fits the lock but also communicates correctly with your car’s electronic systems. Additional Tips for Key Code Location Record Key Codes: If you find your key code, make sure to record it somewhere safe. This will save you time if you need another replacement in the future. Ask About Spare Keys: If you’re contacting a dealership or manufacturer, ask if they can provide a spare key at the same time, especially if you’re prone to losing keys. Consider a Key Tracking System: For those who frequently lose keys, consider investing in a key tracking system or a digital key organizer where you can store key codes and important information. Locating your key code is a crucial step in the process of replacing a lost or broken key. By carefully inspecting your key and lock, reviewing any relevant documentation, contacting the manufacturer or dealer, or seeking help from a professional locksmith, you can ensure that your replacement key is accurate and functional. Taking these steps not only saves time and money but also provides peace of mind in knowing that you have a reliable solution for key replacement.

How to Protect Your Car Key Fob from Relay Attacks
25.04.2025

How to Protect Your Car Key Fob from Relay Attacks

Car theft has entered the digital age — and unfortunately, so have the thieves. As car manufacturers move toward keyless technology, a new type of threat has emerged: the relay attack. Unlike traditional break-ins, this high-tech method allows criminals to steal a vehicle without touching the keys — or even breaking a window. Imagine this: your car is parked safely outside your house. Your key fob is inside, hanging on a hook by the front door. You're fast asleep. But outside, two individuals with small electronic devices are working together. One stands near your front door, scanning for a signal from your key fob. The other waits by your car. Within seconds, your key’s signal is captured, extended, and transmitted to your car. It unlocks, starts, and drives away — and you might not notice until morning. This is not science fiction. It's called a relay attack , and it's one of the fastest-growing vehicle theft methods worldwide. Why Relay Attacks Are So Effective The key to this technique is exploiting the constant communication between your car and its fob. Most keyless entry systems are designed for convenience — you don’t even need to press a button. The car automatically detects the presence of the key fob and unlocks when you approach. This convenience is exactly what makes it vulnerable. Relay devices — which are cheap, portable, and easy to use — can mimic the signal and trick the car into thinking the key is nearby, even when it’s inside your home. Security experts have raised the alarm about this method for years, but many drivers still don’t realize how easily their vehicles can be accessed. In the UK alone, keyless car theft now accounts for more than 90% of vehicle thefts involving high-end models, according to the AA. And with the rise of online tutorials and black-market tools, the problem is growing globally. So, What Can You Do to Stay Safe? Fortunately, protecting your vehicle doesn’t require advanced tech or a huge investment — just awareness and a few smart habits. One of the most effective ways to block relay attacks is also the simplest: store your keys in a signal-blocking container . Often called a Faraday pouch or Faraday box, this lined case prevents radio signals from escaping. When your keys are stored inside, they can’t be scanned or cloned, no matter how close a thief gets to your home. Placement also matters. Many drivers leave their keys near the front door or on an entryway table — spots that are easy to access from outside. Moving your keys to the center of your home, an upper floor, or even a metal box can reduce signal exposure dramatically. Some newer key fobs allow you to manually disable the signal when it’s not in use. This feature is often hidden in the manual and rarely mentioned by dealers. Taking a moment to learn whether your key supports this — and how to activate it — can make a big difference. It’s also worth checking whether your vehicle’s software is up to date. Many automakers periodically release firmware updates that strengthen encryption or reduce signal range. In some cases, updates can even detect and block suspicious unlock attempts. And while it may seem old-fashioned, physical security still works . Devices like steering wheel locks or gear shift immobilisers can be powerful visual deterrents. Even if a thief manages to unlock your vehicle, the sight of a bulky lock inside may be enough to send them looking for an easier target. If you're looking for practical solutions beyond GPS , check out our blog: Do Car Keys Have GPS? What You Need to Know About Key Tracking . In summary, here are a few key takeaways to keep your keys and vehicle safer: Store your fob in a signal-blocking pouch or metal container Keep keys away from entry points like doors or windows Disable keyless signals if your fob supports it Update your car’s firmware regularly Use visible anti-theft devices as a deterrent Looking Ahead: Smarter Cars, Smarter Drivers Relay attacks are part of a larger trend — one where modern technology makes life more convenient, but also creates new risks. Just like we’ve learned to secure our phones and passwords, we now need to think about how we secure our vehicles. As carmakers explore more secure solutions — like Ultra Wideband (UWB) tech and biometric verification — drivers still need to take responsibility for their vehicle’s safety. The tools are already out there, and many of them cost less than a meal out. It’s not just about avoiding theft; it’s about peace of mind. So next time you get home, before tossing your keys on the hallway table, take a second to think: are they really safe there?

Pioneering Innovations in Cars: A Journey Through 150 Years
25.07.2024

Pioneering Innovations in Cars: A Journey Through 150 Years

The automotive industry has undergone extraordinary changes in the last 150 years. From the earliest steam-powered engines to today’s smart, electric vehicles, cars have become symbols of innovation, convenience, and human progress. This article explores the most groundbreaking innovations that have defined car history, driving us into the future. 1. The Birth of the Car (Late 19th Century) The late 1800s marked the beginning of the automobile industry with the invention of the first cars. Key Milestone: Karl Benz’s creation of the Benz Patent-Motorwagen in 1885-86 was a game-changer. Impact: For the first time, individuals could travel independently without relying on horses or trains. This innovation laid the foundation for a new era of personal transportation. 2. The Rise of Mass Production (Early 20th Century) The early 1900s brought cars to the masses through assembly line production. Key Milestone: Henry Ford’s introduction of the moving assembly line in 1913 revolutionized car manufacturing. Impact: Cars became affordable and accessible to ordinary people, leading to the widespread adoption of automobiles. The Model T became a symbol of this industrial transformation. 3. The Era of Safety Innovations (1950s–1970s) As cars became common, safety innovations took center stage. Key Milestones: Seatbelts: Volvo introduced the modern three-point seatbelt in 1959. Airbags: Developed in the 1970s to provide additional protection during crashes. Impact: These innovations drastically reduced injuries and fatalities, making cars safer for all passengers. Safety continues to be a driving force behind car innovations today. 4. Fuel Efficiency and Environmental Consciousness (1980s–2000s) The late 20th century witnessed a shift towards eco-friendly car innovations. Key Milestones: Introduction of hybrid cars like the Toyota Prius (1997). Stricter emission regulations led to cleaner, more efficient engines. Impact: Consumers and manufacturers started prioritizing fuel efficiency and reducing environmental impact. This period laid the groundwork for the electric car revolution. 5. The Digital Revolution in Cars (2000s–2020s) Modern cars are no longer just machines; they’re smart devices on wheels. Key Innovations: GPS Navigation: Real-time navigation made travel simpler and safer. Infotainment Systems: Touchscreens and voice controls for entertainment and information. Driver Assistance: Features like parking sensors, adaptive cruise control, and collision alerts. Impact: Technology has transformed driving into a more connected, comfortable, and efficient experience. 6. Electric and Autonomous Cars (The Future is Here) The future of cars lies in sustainability and autonomy. Key Innovations: Electric Vehicles (EVs): Companies like Tesla popularized EVs, offering zero-emission driving. Autonomous Driving: Self-driving technology is advancing rapidly, promising safer and more efficient transportation. Impact: Electric and autonomous cars represent a monumental leap towards reducing environmental impact and redefining mobility. The next 50 years will likely see even bolder transformations. From steam engines to self-driving electric vehicles, the car has come a long way. Each era brought innovations that shaped not just how we travel but also how we live. As technology continues to evolve, the possibilities for cars seem endless. Whether it’s improving safety, reducing emissions, or offering autonomous capabilities, cars will remain at the heart of human progress.

Why Your Car Remote Isn’t Working and How to Fix It
07.01.2025

Why Your Car Remote Isn’t Working and How to Fix It

Car remotes have become an essential part of modern vehicle ownership, offering convenience and added security. However, when they stop working, it can lead to frustration and delays. If you’ve ever faced a malfunctioning car remote, don’t worry—you’re not alone. Here’s a guide to help you understand the common reasons why your car remote might fail and how you can fix the issue quickly and affordably. 1. Dead Battery: The Usual Suspect One of the most common reasons for a non-functional car remote is a dead battery. Over time, the small coin batteries in your remote lose their charge, making the remote unusable. Signs of a Dead Battery: Reduced range, inconsistent functionality, or complete failure to respond. How to Fix It: Replace the battery with a compatible CR-type coin battery. Check your car manual or the remote’s casing for the correct battery type. Pro Tip: Always keep a spare battery in your glove compartment to avoid getting stranded. 2. Signal Interference: The Invisible Barrier Signal interference can block communication between your remote and your car. This can happen in areas with high electromagnetic activity or if the remote’s signal is weakened. Common Causes: Proximity to cell towers, Wi-Fi routers, or even other key fobs . How to Resolve It: Move closer to your car and try again. Change your location if you’re in a crowded parking area. Keep your remote away from other electronic devices that might cause interference. Prevention Tip: Avoid storing your car remote near electronics when not in use. 3. Remote Needs Reprogramming Sometimes, a car remote loses its programming, which is essential for communicating with your car. This can happen after battery replacement, electrical system resets, or software glitches. Signs Your Remote Needs Reprogramming: The buttons don’t respond, or the remote only works intermittently. What You Can Do: Check your car manual for DIY reprogramming instructions. If DIY methods fail, consult a professional locksmith or your car dealer for assistance. Pro Tip: Always reprogram your remote immediately after replacing its battery to avoid compatibility issues. 4. Physical Damage: More Than Just Wear and Tear Daily use, accidental drops, or exposure to moisture can damage your car remote, leading to malfunction. The internal components, such as the circuit board, are particularly sensitive. Signs of Damage: Cracks on the casing, loose buttons, or water ingress. How to Address It: For minor issues, replace the remote casing or repair loose buttons. If the circuit board is damaged, you’ll need a replacement remote. Preventative Measures: Use a protective key cover to shield your remote from damage. Keep your remote away from water and extreme temperatures. 5. Faulty Car Receiver: The Problem Isn’t Always the Remote In some cases, the issue lies with your car’s receiver rather than the remote. If the receiver is damaged or malfunctioning, it won’t recognize signals from the remote. How to Diagnose: If multiple remotes fail to work with the same car, the receiver might be the issue. Test your remote on a similar vehicle, if possible, to rule out the remote as the problem. How to Fix It: Consult a professional mechanic to inspect and repair the car’s receiver system. General Tips to Keep Your Car Remote Functional Prevention is better than cure, especially when it comes to car remotes. Here are some tips to avoid future issues: Regular Maintenance: Inspect your remote periodically for wear and tear. Store It Safely: Keep your remote in a safe, dry place to avoid accidental damage. Backup Plan: Always have a spare key or remote handy for emergencies. Invest in a Tracker: Attach a Bluetooth tracker to your remote for easy location if it gets misplaced. When to Seek Professional Help While many car remote issues can be resolved with DIY methods, some problems require professional assistance. If your remote still doesn’t work after troubleshooting, consult a locksmith or an automotive specialist. They can help with repairs, replacements, and reprogramming at an affordable cost. Don’t Let a Faulty Remote Slow You Down A malfunctioning car remote can be a hassle, but most issues are fixable with a little know-how. Whether it’s a dead battery, signal interference, or physical damage, understanding the root cause will help you resolve the problem efficiently. With proper care and maintenance, your car remote will continue to offer the convenience and security you rely on every day.

Logo
More options Accept all Reject all
This website uses cookies

We use cookies to personalise content and ads, to provide social media features and to analyse our traffic. We also share information about your use of our site with our social media, advertising and analytics partners who may combine it with other information that you’ve provided to them or that they’ve collected from your use of their services.

Chat with us